Title: PROBLEM SOLVING
1PROBLEM SOLVING
OLD METHOD Component Name Gear Stay Component
weight 182Kgs Number of Castings per Mold
1nos. Total Good Casting wt 182Kgs Total
Pouring wt 310kgs Yield 58.5
PROBLEM DESCRIPTION Component getting rejected in
Ultrasonic testing for back wall echo loss.
2Picture shows Metal Filling at various
intervals The colour scale shows the temperature
at each location
3Picture shows Solidification at various
intervals The colour scale shows the of Liquid
metal available
Isolated region
4Picture shows the possible Shrinkage area
This defect location exactly matches with
customer complaint
Shrinkage location
5PROBLEM SOLVING
- Corrective Action
- Gating changed
- Feeder size increased and number of feeders
reduced 2
6Picture shows Metal Filling at various
intervals The colour scale shows the temperature
at each location
7Picture shows Solidification at various
intervals The colour scale shows the of Liquid
metal available
8Picture shows the porosity locations There is no
defect inside the casting
9- Finding after implementation of this method
- Hotspot moved to feeder and there is no defect
noticed inside the casting. - Yield also increased by 10
- 100 UT o.k and mold erosion problem eliminated.